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Expander Demonstrator FLPP_134.qxd 6/5/08 12:37 PM Page 34 Expander Demonstrator Jérôme Breteau & Jean-Noël Caruana Future Launcher Preparatory Programme, Directorate of Launchers, ESA HQ, Paris, France he technical difficulties encountered by other spacefaring countries in similar T ‘expander-cycle’ engine projects show how demanding it is to master this kind of technology. So the achievements of ESA’s Future Launchers Preparatory Programme (FLPP) Expander Demonstrator Project, including several European ‘firsts’, are essential contributions to the development of future cryogenic upper-stage engines. Introduction In launch vehicles, one of the key enabling technologies is the propulsion system, but this is complicated to acquire and takes a long time in development. This is especially true for upper-stage engines, where use of cryogenic propellants such as liquid hydrogen and oxygen and reignition capability are essential in order to reach high-energy orbits with heavy payloads. Upper-stage engines also operate in specific conditions (vacuum, micro- gravity) that are difficult to reproduce on Earth, and involve significant development risks that have to be mitigated. esa bulletin 134 - may 2008 35 FLPP_134.qxd 6/5/08 12:37 PM Page 34 Expander Demonstrator Jérôme Breteau & Jean-Noël Caruana Future Launcher Preparatory Programme, Directorate of Launchers, ESA HQ, Paris, France he technical difficulties encountered by other spacefaring countries in similar T ‘expander-cycle’ engine projects show how demanding it is to master this kind of technology. So the achievements of ESA’s Future Launchers Preparatory Programme (FLPP) Expander Demonstrator Project, including several European ‘firsts’, are essential contributions to the development of future cryogenic upper-stage engines. Introduction In launch vehicles, one of the key enabling technologies is the propulsion system, but this is complicated to acquire and takes a long time in development. This is especially true for upper-stage engines, where use of cryogenic propellants such as liquid hydrogen and oxygen and reignition capability are essential in order to reach high-energy orbits with heavy payloads. Upper-stage engines also operate in specific conditions (vacuum, micro- gravity) that are difficult to reproduce on Earth, and involve significant development risks that have to be mitigated. esa bulletin 134 - may 2008 35 FLPP_134.qxd 6/5/08 12:37 PM Page 36 Launchers Expander Demonstrator In 1998 ESA, CNES and Arianespace project called the ‘Cryogenic Reignitable (TRL) of the engine and its decided to develop an enhanced Upper Stage Engine – Expander components, currently estimated cryogenic upper-stage for the Ariane-5 Demonstrator’. between 3 and 5, depending on the launcher in order to respond to the subjects under study, must be raised to rapid evolution of the global Project Objectives level 6 (prototype test in a relevant commercial market towards more heavy The main aim of the FLPP Expander environment), in order to properly assess payloads. In recognition of the quick Demonstrator Project is to supply the risks, cost and duration of a further emergence of this new commercial need elements allowing a sound, informed development phase up to qualification and the comparatively long decision about the next steps in the (TRL 8). The definition of T development time of a propulsion development of the cryogenic reignit- Most engine components have already system, it was decided to select a two- able upper-stage engine. More precisely, reached a TRL of 5 and are close to step approach to increase Ariane-5’s in- the implementation of this objective achieving the target of TRL 6. The most the opera ydrogen environments, (including reliability, projected mass and orbit delivery capability. requires detailed studies of the engine’s significant issues to process are linked to propellant mixtur egarding ‘embrittlement’ performance, production cost, develop- The first step was the development of operating domain and assessment of its component life duration and per- feeding conditions); ment duration and cost). an adaptation of the existing Ariane-4 design through extensive, full-scale formance assessment or behaviour in – nominal perfor xperience for the engine. This exercise is initiated at an early H10 propulsion system for a new upper- engine testing in hot-firing conditions. operational conditions (pollution, exploration of stage of the launcher design because stage called ESC-A. The second step This will make it possible to increase transient conditions, etc.). The Tech- (thrust, mixture ra the FLPP Expander experience and theory show that an involved the development of an our knowledge and understanding of nological Readiness Levels of some turbopumps); oject is to overcome the overall optimised design is not necessarily adaptation of this stage to create the expander-cycle engine operations and innovative components, like the Nozzle – characterisation of ed in the assembly of optimised subsystems. ESC-B version with a new cryogenic technologies, yielding propulsion data Extension Deployment system or the stability of epare The highest performance engine, optimal engine, the ‘Vinci’. The initial ESC-B for launcher system optimisation, in igniter, are lower compared to other conditions; ble at a further stage. from a propulsion point of view, might flight was planned in 2006, following on addition to the proper development and engine technologies and require – first experience f not be the best global solution due to from the introduction of ESC-A. safeguarding of the relevant European dedicated subsystem technology tests if integrat ade-off at stage and specifications and constraints at a higher However, although Ariane-5 ECA competencies in cryogenic propulsion. It they are to be improved. system level. There is a continuous entered operational service, a should be noted that the development of There are many more significant – ated exchange of data between the engine and combination of factors including a the Vinci engine, before it was inter- technological steps in the FLPP d the launcher system throughout the downturn in the commercial market rupted, had just reached a stage that Expander Demonstrator Project that entire preliminary design process, starting delayed and then stopped the allowed the Expander Demonstrator contribute to the improvement of the – or with high-level performance data, such as development of the ESC-B stage and the Project to gain direct experience at the engine TRL. These are: the following: Vinci engine. engine hot-firing test level. – definition of an optimised starting . – thrust level; At the same time, launch system and shutdown sequence with respect – mixture ratio; studies within FLPP showed clearly the Assessment of operating domain and to progressivity, duration and – – specific impulse; need for a versatile, high-performance, design maturation propellant consumption; – restart capability; evolved cryogenic upper-stage engine The Technological Readiness Level – verification of engine stability over the – thrust-to-weight ratio; capable of delivering payloads to all – – physical interfaces; kinds of orbits, ranging from Low Earth Orbit up to exploration missions in deep Expander closed-cycle engine: how does it work? space. A high-performance upper-stage The expander thermodynamic cycle is a ‘closed cycle’, meaning that the propellants flow together engine appeared to be a central element through the thrust chamber, hence maximising the for the future launcher scenarios of the specific impulse, an indicator of engine FLPP, and a cryogenic expander engine performance. The combustion chamber pressure offered high expectations in terms of is higher than the tank pressure (~60 bars performance and reliability. compared to 2–5 bars). This pressure rise is It became quickly obvious that the ensured via two centrifugal turbopumps driven by availability of a set of expander-cycle turbines installed on the pump shafts. upper-stage engines offered a unique opportunity to progress in the The turbines are activated by the flow of high- preparation of upper-stage engines for pressure gaseous hydrogen obtained by all future launcher configurations. circulating the hydrogen pump discharge flow It was, therefore, decided at the end of around the hot combustion chamber walls. After 2005 to transfer the management and being heated up in the combustion chamber jacket, the hydrogen flows existing assets of the former Vinci through the turbines and is injected into the combustion chamber. Then, mixed with the liquid oxygen flow, it combusts and produces the hot-gas flow development to the FLPP in order to that provides the rocket engine’s thrust. form the basis of a demonstration 36 esa bulletin 134 - may 2008 www.esa.int www.esa.int esa bulletin 134 - may 2008 37 FLPP_134.qxd 6/5/08 12:37 PM Page 36 Launchers Expander Demonstrator In 1998 ESA, CNES and Arianespace project called the ‘Cryogenic Reignitable (TRL) of the engine and its decided to develop an enhanced Upper Stage Engine – Expander components, currently estimated cryogenic upper-stage for the Ariane-5 Demonstrator’. between 3 and 5, depending on the launcher in order to respond to the subjects under study, must be raised to rapid evolution of the global Project Objectives level 6 (prototype test in a relevant commercial market towards more heavy The main aim of the FLPP Expander environment), in order to properly assess payloads. In recognition of the quick Demonstrator Project is to supply the risks, cost and
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